Real-time Visibility. RFID-enabled Applications for Asset Tracking. Deployment Guide. Delivering Real-Time Visibility to the Enterprise

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Deployment Guide

Real-time Visibility

RFID-enabled

Applications for

Asset Tracking

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Tracking Assets Across the Value Chain

Automating and error-proofing even a single business process can deliver a significant return on investment.

Process-specific projects often pay for themselves within 9-12 months, and are targeted in one or more of

the following areas:

The use cases on the following pages illustrate

specific areas where asset tracking can be

automated in multiple points in the value chain.

By adding real-time visibility to business systems, RFID and Auto-ID technology deliver process efficiency

and cost savings. Optimizing asset utilization and indirect materials management across multiple nodes in

the value chain decreases inventory and handling costs while increasing product availability.

Manufacturing / Warehousing Shipping

SUPPLIERS

2. 3. Trailer Yard 4. Receiving 1.

CUSTOMERS



Receiving



Reusable Container Tracking



Component / Subassembly Tracking



Tool Tracking



Jig/Mould Tracking



Whole Goods Tracking



Shipping

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OAT worked with a leading Aerospace Manufacturer

to real-time enable their inbound logistics processes

with RFID.

The result: a 75% reduction in handling time and more

effective labor allocation, by focusing on exception

handling vs. day to day operations.

RFID Applications in Receiving

1. Receiving



Automate receipt & verification of incoming goods from suppliers

Auto-ID Application



Compare received goods with content manifest or ASN



Flag priority items by comparing order number and special instructions



Expedite the receipt assets which need to be deployed immediately



Quarantine and track non-scheduled shipments

Web Services Integration Options

for ERP, WMS and Asset Management Systems



Automated tracking and reliable identification of shipments as they are received



Significantly reduced error rates and costly correction processes



Staff focused on exceptions rather than administrative paperwork



Minimized need for safety stock and expedite costs to cover lost shipments

Auto-ID Value Add

Manufacturing / Warehousing Shipping SUPPLIERS 2. 3. Trailer Yard 4. Receiving 1. CUSTOMERS

Container

Tracking



Track reusable containers, dunnage and contents from location to location

Auto-ID Application



Automatic confirmation of Advanced Shipping Notices, Order Numbers, Cost Centers



Track container pedigree/dunnage as contents are added and removed



Alert staff when container needs to be placed back into service or is received at wrong location

Web Services Integration Options

for ERP, WMS, Asset Management Systems



Optimize movement and usage to improve operating efficiency, asset utilization



Reduce size of container fleet

Auto-ID Value Add

!

Alert! Work Order Y453-D7112 is a RUSH ORDER

Please expedite

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RFID & Auto-ID Devices & Sensors

RTLS, Wi-Fi, Barcode, Active/Passive RF, Alarms..

OATxpress

™

OATdevice

manager

™

ERP / WMS / Asset Management System

Send manifest fulfillment details Read package, asset, contents Validate against manifest Get delivery manifest

details for dock door4

Execute

ERP/WMS transactions (upd ate goods issue, send ASN, etc.) & capture event data Get Order Details

from ERP/WMS Assign/schedule delivery to site

Receipt at dock door4 Operator feedback • Validating manifest details, ASN against physical shipments

Sample Process Flow

Receiving

Receiving : Functional Process Flows

1. RFID & Auto-ID Devices & Sensors

OATxpress

™

OATdevice

manager

™

ERP / WMS / Asset Management System

Validate against container fleet requirements Associate container number and contents Execute

ERP/WMS transactions (update goods issue, send ASN, etc.) & capture event data

Obtain list of

expected receipts Set status to “Received”

Receive container at

dock 11, set date/time feedbackOperator

• Validating order & manifest details against physical containers and their contents

Container

Tracking

!

Alert! Container 14562 is needed for a RUSH ORDER Please expedite

!

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Tool

Tracking

Component &

Subassembly

Tracking

RFID Applications in Manufacturing / Warehouse

2. 

Automate barcode-based Work-in-Process tracking to document product lineage from components to subassemblies to finished product

Auto-ID Application



Automatically update work-in-process status and component serialization as products are assembled



Compare subassemblies with bill of materials



Provide configurable settings to trigger alerts when

assets are missing or manifest is incomplete

Web Services Integration Options

for ERP, WMS, Asset Management Systems



Fewer errors, shorter lead time, more thorough documentation



Reduced search time and expedite costs



Reduced inventory and storage costs



Lower likelihood of rework, leading to increased productivity

Auto-ID Value Add



Automate check-in, check-out, real-time track and trace of specialized tools, molds and indirect materials, for manufacturing, maintenance & overhaul operations

Auto-ID Application



Compare and update physical tool inventory against stock across multiple tool stores



Update calibration status and alert operator when recalibration is due

Web Services Integration Options

for ERP, WMS, Asset Management Systems



Reduced expedite costs and excess inventory to compensate for lost tools



Reduced labor costs for tracking down missing tools and managing administrative paperwork



Improved assembly and service efficiency

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RFID & Auto-ID Devices & Sensors

OATxpress

™

OATdevice

manager

™

ERP / WMS / Asset Management System

Manufacturing / Warehouse : Functional Process Flows

2.

• Documenting and verifying component parts during the assembly process

Tool

Tracking

Component &

Subassembly

Tracking

• Managing tool stores and calibration schedule

Sample Process Flow Send service _details

Read tool information

Validate against maintenance schedule Get specialized tool

requirements and location

Update service history, information Get BOM details

from ERP/ WMS/ Asset Mgt System

Update with new location status

Check out tool

at store #3 feedbackOperator Alert!

Tool# 16554005 is due for scheduled calibration

RFID & Auto-ID Devices & Sensors

OATxpress

™

OATdevice

manager

™

ERP / WMS / Asset Management System

!

Send work order status Read component serial #s, batch #s, test data Validate against Work Order Get assembly instructions and

component list for workstation #3

Execute ERP transactions (update component inventory, work order status) & capture event data Get Work Order

details from ERP/MES Assign work order to operator Receipt at

workstation #3 feedbackOperator

Alert! Part # TR783-065 is recalled. Please substitute Part# CR782-0621

!

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Shipping

RFID Applications in Shipping

3. 

Automated Advanced Shipping Notices (ASNs) and verification of outgoing orders

Auto-ID Application



Expedite rush shipments



Verify individual items within each shipment



Verify final destination, carrier, dock door and customs clearance



Flag rush shipments by comparing order number & special instructions

Web Services Integration Options

for ERP, WMS, Asset Management Systems



100% automated tracking & reliable confirmation of assets as they are shipped



Significant reduction in error rates and costly correction processes



Focus staff on exception handling vs. administrative paperwork

Auto-ID Value Add

Jig

Tracking



Automated check-in, check-out, real-time track and trace of specialized jigs and other indirect materials used for shipping high-value assets

Auto-ID Application



Track and update location and status of specialized jigs and the assets they transport



Alert operator when jig inventory runs below a specified level

Web Services Integration Options

for ERP, WMS, Asset Management Systems



Improved utilization of specialized equipment and transport vehicles



Reduced expedite costs and excess inventory to compensate for lost materials



Reduced labor costs for tracking down missing items and managing administrative paperwork



Improved delivery and service efficiency

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RFID & Auto-ID Devices & Sensors

OATxpress

™

OATdevice

manager

™

RFID & Auto-ID Devices & Sensors

OATxpress

™

OATdevice

manager

™

Shipping: Functional Process Flows

3.

• Verifying outgoing shipments, validating assets against delivery manifest

• Documenting and confirming indirect material availability with an automated check-in/check-out process

Jig Tracking

Shipping

Send manifest fulfillment details Read package, order #, contents Validate against manifest Get delivery manifest details for dock door 4

Execute ERP/WMS transactions (update goods issue, send ASN, etc.) & capture event data

Get Order Details

from ERP/WMS Assign/schedule delivery to site

Final inspection

at dock door 4 feedbackOperator

Send order ID, jig ID, product ID and final destination Receive jig at loading area, Zone C Validate against inventory/ location table Get location details for jig/other transport materials

Update jig/transport material inventory Confirm delivery schedule,

required transport materials from ERP /EWM/ Field Service/ Asset Management

Assign jigs/transport materials to Zone C in loading area

Receive goods to be shipped in

loading area, Zone C feedbackOperator

Jig 77105 assigned to outgoing order AG016681

ERP / WMS / Asset Management System

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RFID Applications in the Trailer Yard

4. Yard

Management



Automate check-in and dispatch, real-time track and trace of finished goods, yard trailers and contents

Auto-ID Application



Compare trailer contents with manifests, ASNs and work orders



Update inventory and location of finished goods, place replenishment orders as needed



Flag rush shipments by comparing order number and special instructions

Web Services Integration Options

for ERP, WMS, Asset Management Systems



Reduced error rates and costly correction processes



Reduced expedite costs and safety stock to cover lost

shipments



Reduced labor costs for tracking down missing assets and managing administrative paperwork



Reduction in asset shrinkage



Improved shipping estimates, leading to better customer service

Auto-ID Value Add

Whole Goods

Tracking



Automate check-in and check-out, real-time track and trace of finished goods

Auto-ID Application



Compare expected assets with physical assets



Update inventory and location of finished goods, place

replenishment orders as goods are transferred or sold



Automatically locate assets across multiple yards

Web Services Integration Options

for ERP, WMS, Asset Management Systems



Reduced labor costs and expedite costs for tracking down and/or replacing missing assets



Reduction in asset shrinkage



Improved product availability, leading to better customer service

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RFID & Auto-ID Devices & Sensors

OATxpress

™

OATdevice

manager

™

RFID & Auto-ID Devices & Sensors

OATxpress

™

OATdevice

manager

™

Trailer Yards: Functional Process Flows

4.

• Verify asset location, configuration & status across multiple facilities

• Verifying asset location and inventory counts during check-In/ check-out process

Yard

Management

Whole Goods

Tracking

Send manifest fulfillment details Read product#, model #, at Dallas TX loading area Validate against manifest Confirm location of

specific product, model #, Dallas TX facility

Update shipment data and decrement inventory in ERP/ WMS / Asset Management System

Inbound customer request for Product 786456, Model AP4568 Schedule delivery from Dallas TX to customer site Operator feedback Send configuration details

Read product ID, trailer ID, location

Validate against inventory/ location table Get location details for trailer Update yard management map Get delivery schedule from

ERP /WMS / Asset Management System

Assign finished goods to zone within laydown yard

Receipt at

laydown yard feedbackOperator

Pinpoint goods location in

ERP / WMS / Asset Management System

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Real-Time enabling the Value Chain

Supply Chain Logistics & Distribution Manufacturing / Assembly Lines Maintenance & Reverse Logistics Asset Attributes to Track:

•

Component Parts

•

Supplier

•

Batch Number

•

Due Date

•

Carrier

•

Order Number

•

Order Contents

•

Final Destination

•

Due Date

•

Work-in-Process Status

•

Indirect Materials Reqd

•

Test Results

•

Custom Order Details

•

Service History

•

Replacement Parts

•

Part Expiration Date

•

Service Due Date

Processes

to Enable: SourcingShipping/ Receiving Container Tracking Shipping/Receiving Yard Management Transportation Jig Tracking

Whole Goods Tracking

Shipping/Receiving Line-side Replenishment Assembly Jig Tracking Tool Tracking Line-side Maintenance Reverse Logistics Enterprise Systems to Enable ERP MMS WMS Enterprise Asset Mgt ERP WMS Enterprise Asset Mgt ERP MMS Enterprise Asset Mgt WMS Field Service MRO Enterprise Asset Mgt Infrastructure

to Enable Barcode, RFID,Contact Memory Buttons, Wi-Fi

Barcode, RFID, Wi-Fi,

RTLS, GPS Barcode, RFID, CMBs, Wi-Fi, PLCs, Stack Lights & other sensors

Barcode, RFID, CMBs, Wi-Fi, RTLS, GPS

Quantifying

Value: Increased Forecast Accuracy Reduced Safety Stock Reduced Expedite Costs

Streamlined Shipping Costs

Increased Order Accuracy & Customer Satisfaction

Improved Product Quality, Fewer Returns

Reduced Downtime Reduced Scrap & Rework

Reduced Expedite Costs

Increased Time in Service Fewer Audits & Regulatory Fines Reduced Maintenance and Repair Costs

1.

2.

3.

4.

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Critical Success Factors for Manu

Leverage your enterprise systems

Manufacturers and Service Providers make significant investments in ERP,

WMS, Asset Management and MRO systems. Enriching these systems with

RFID, Auto-ID or sensor data can dramatically reduce the time and cost of

deployment.

Take advantage of real-time data

Don’t just capture RFID and Auto-ID information in a data warehouse. Take full

advantage of real-time alerts and insights to reduce error rates and improve

productivity.

Focus on cost reduction

Many companies can realize significant savings in expedite, transportation,

labor and inventory costs by real-time enabling error-prone process areas

such as Shipping & Receiving, Container Tracking and Yard Management.

Make sure your initial project has room for growth

Select a proven RFID & Auto-ID application platform with broad device support

and deployment flexibility, so that you can evolve and scale easily.

Start with configurable packaged solutions

RFID & Auto-ID packaged solutions are much faster to test and deploy, and can

often be easily configured for an organization’s specific needs, without

requiring custom development.

Begin with the end in mind

Don’t lose sight of your business goals. Track and adjust your metrics along

the way and plan for continuous improvement.

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Corporate Office:

OATSystems

309 Waverley Oaks Road, Waltham, MA 02452 USA 781-907-6100 International Sales: OATSystems 68 Lombard Street London EC3V 9LJ United Kingdom +44 20 7868 1704 www.oatsystems.com

About OATSystems

OATSystems, Inc., division of Checkpoint Systems, Inc., is a recognized radio-frequency identification

(RFID) solution leader with software that empowers businesses to achieve competitive advantage and

ROI from RFID enabled applications. As a pioneer in developing RFID & Auto-ID technology,

OATSystems has been setting the standards in RFID for over half a decade and is responsible for

industry firsts that include the largest scale and largest scope of deployments, as well as the most

innovative approaches to providing enterprise-wide RFID solutions.

OATSystems’ multinational client base consists of over 100 customers in retail, consumer packaged

goods, consumer electronics, manufacturing, life sciences, aerospace and defense.